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1 Lighthouse Project for the Demonstration of Hydrogen Fuel Cell Vehicles and Their Refuelling Infrastructure in Scandinavia Final Report Status: Final Public Report Date: 28 February 2013 Authors: Ulrich Bünger, Peter Bremer, Sofia Capito, Tim Faber, Teresa Fickler, Sae Hoon Kim, Steffen Møller-Holst, Martin Svensson, Flemming Wennike, Mikael Sloth, Federico Zenith This project is co-financed by European funds from the Fuel Cells and Hydrogen Joint Undertaking under FCH-JU Grant Agreement Number The project partners would like to thank the EU for establishing the Fuel cells and hydrogen framework and or supporting this activity.

2 Disclaimer This document is the result of the collaborative work of the H2moves Scandinavia partners. The results of the EU Hydrogen Road Tour were subsequently elaborated and are presented here in a coherent manner, which involved extensive stakeholder involvement. The findings presented in this document were reviewed by the H2mS project partners to ensure broad general agreement with its principal findings and perspectives. However, while a commendable level of consensus has been achieved, this does not mean that every consulted stakeholder necessarily endorses or agrees with every finding in the document. The producer of this document is the sole responsible for its content and interpretations.

6 H2moves Scandinavia - Final Public Report 6 Executive Summary The H2moves Scandinavia project has been a unique opportunity to showcase the reliability and hence marked preparedness of hydrogen operated fuel cell cars under daily driving conditions, even in harsher climate conditions pertinent to Oslo and Copenhagen. In its pioneering role it has suffered from a number of drawbacks specifically as a consequence of the aftermath of the 2008/09 economic crises; several key partners dropped out and others had to be convinced of this outstanding opportunity to participate in showcasing this technology. Even though it has been the very first of a chain of Lighthouse Demonstration Projects (LHP), funded by the public private partnership Fuel Cell and Hydrogen Joint Undertaking (FCH JU), it has generated several valuable strategic insights which have been summarised in the table below. The most outstanding result is that the hardware of fuel cell vehicles and the hydrogen refuelling stations (a stationary one in Oslo Gaustad and a moveable one for use in the European Road Tour) have proven to be unexpectedly reliable. Except of a compressor failure which downed the Gaustad station for two months availabilities of % on a monthly basis could be reported and no single accident was encountered. The other important result of the project has been the wide dissemination of the results, both by high level events, but specifically through the possibility for VIP and public ride&drives. All this has cumulated in the European Hydrogen Road Tour, posed as the major hydrogen and fuel cell event in During this tour H2mS could not only provide valuable insights into the learnings from everyday driving in the Nordic countries or offer free rides strategic, but also collect valuable feedback.

7 H2moves Scandinavia - Final Public Report 7 The echo from the regions visited was overwhelmingly positive and relevant people announced they would investigate into supporting the hydrogen infrastructure build up or start own demonstration activities. A firework of single events has made the EU Road Tour become a real success, among others by participation in the EcoDolomite electric vehicle race in Bolzano, a visit with own booth at the Paris Motor Show and of London s livingroom, the London s Mayor office, signing of an Memorandum of Understanding by the Nordic countries with several international automobile companies in Copenhagen to name but a few. Also locally in the Nordic countries, the vehicle customers have used their FCEVs for promotional purposes, such as SINTEF for a Ride&Drive event in Trondheim in combination with an inner city rally (Daimler B-Class F-CELL), as ZERO for a trip to Monte Carlo of about 2,200 km refuelling at hydrogen stations along the route (Hyundai ix35 FCEV) or as H2 Logic as emission free support vehicle for the Denmark leg of the Giro d Italia bicycle race. It goes without saying that all events had a very good media coverage, partially also at international level. Another aspect which is typically forgotten in this context, but an important ingredient for a successful demonstration project is the building of stakeholder networks. On one side, the project partners have established a trustful cooperation, and here specifically the different approaches by stakeholders from the Nordic countries, from central Europe and from South Korea have contributed to a better understanding of the cultural differences but for the same technical and societal goal of introducing fuel cell vehicle technology. On the other side, external stakeholders such as the technicians trained in the automotive workshops in Oslo and Copenhagen and certification or safety authorities in both countries got involved and learnt about the market readiness of fuel cell vehicles. As a good example, the rule banning gas fuelled cars from belowground parking garages, which had been established the very same moment when H2mS s demo phase commenced, was repealed after only few weeks of negotiation between the automobile manufacturer and authority. The consortium is satisfied about the outcome of the project. The hardware lives on in Oslo and Copenhagen outside the framework of the H2mS project, the FCEVs collecting further miles on Norwegian and Danish roads and the refuelling station continuing to serve hydrogen to FCEVs in both growing hydrogen refuelling infrastructure networks. Strategies in both Norway and Denmark and in the other Nordic countries have been developed for a further deployment of the technology. H2mS has contributed an important and visible milestone along these developments.

8 H2moves Scandinavia - Final Public Report 1 8 Introduction The H2moves Scandinavia project is the first European Lighthouse Project for hydrogen, funded by the European Fuel Cells and Hydrogen Joint Undertaking programme, launched by the European Commission and European industry. Main focus of the joint undertaking is to increase the impact of industrial level activities in Europe in this field and to address three major European policy targets: Energy diversity Mitigation of greenhouse gases Increase the share of renewable energies Major car manufacturers have devoted a significant amount of resources towards developing hydrogen powered Fuel Cell Electric Vehicles (FCEVs) that will be mass produced from That is why we took cars from four companies Daimler, Honda, Hyundai and Toyota along the European Hydrogen Road Tour In many of the cities we visited it was the first time the general public had an opportunity to test drive these cars with only water coming out of the exhaust. A fuel cell is a device which can be used to efficiently transform the hydrogen s chemical energy into electricity and heat. Even better, the only emission is pure water. The efficiency of a fuel cell car is twice as high as of a conventional gasoline vehicle, which compensates for loss of energy when producing hydrogen. FCEVs are on a par with today s cars but emit much less noise and emissions. Provided the energy in the hydrogen production is renewable, the environmental impact is compared to conventional internal combustion engine cars near zero. Our ambition is to prepare the European market for FCEVs so the FCEVs you can see here today, will be seen everywhere tomorrow.

9 H2moves Scandinavia - Final Public Report 9 2 Operation of Fuel Cell Vehicles 2.1 Daimler B-Class F-CELL The Scandinavian market and especially Norway is an interesting pilot-market for electric vehicles with fuel cell for many reasons. Norway has the potential to produce green hydrogen (about 95% of the electricity is based on hydropower). The people are very open for new green technologies; the government is supporting green vehicles by exempting them from purchase tax and VAT, on top giving 90% discount on annual road tax. No toll or municipal parking fees are charged and you have free ferry passage and access to bus/taxi lanes. The cold climate is an additional point of interest to test freeze start capability of the vehicles. Furthermore, it seemed like Norway already had a fairly developed hydrogen infrastructure. Having those benefits in mind, the decision was made to participate in the H2moves Scandinavia project with the main testing site Oslo, Norway. After the consortium was founded, Statoil, as the main fuelling station operator in Norway, dropped out of the hydrogen business. Later in the process it was discovered that the existing stations do have some problems with quality and reliability. This led to a delay in delivering vehicles to the Oslo market which had, at this point in time, no 700bar Daimler approved station (according to technical information report SAE J2601). One B-Class F-CELL vehicle was already delivered to Oslo at the end of 2010 in order to prepare the market for the vehicles to come. Many station tests were made at Oslo Økern to assure refueling for the coming fleet of ten B-Class F-CELL vehicles. In August 2011, the vehicles were shipped to the General Agent of Mercedes-Benz Bertel O. Steen. In 2011 it became apparent that the hydrogen dispensed at the Oslo Økern station was contaminated with particles. Within Daimler every station at this point in time (not all stations are in accordance with SAE J2601) has to be accepted by Daimler through a special recommendation process. This process started in Oslo Økern at the end of October 2010 and was continued during The communication vehicle was very useful in this process to support the numerous tests at the Oslo Økern station.

10 H2moves Scandinavia - Final Public Report 10 To protect the fuel cell system from the particles, every single vehicle had to be upgraded with a 2 µm filter. Because of delivery problems of the filters, the process of exchanging the filters kept the aftersales department and also the workshop staff busy for months. With the opening of the well-functioning new project fuelling station Oslo Gaustad (H2Logic), the process of delivering vehicles to final customers started in November A very high interest in the B-Class F-CELL was shown by the customers. The uncertain refuelling situation (it was not sure if Oslo Økern will stay in operation) led some customers to pull out. Eight out of ten B-Class F-CELL vehicles went into customer hands. Two of them remained in the hands of Bertel O. Steen to use them for events and testing of fuelling stations. In addition they were used as Mobility vehicles, while servicing customer cars. Customers, such as the research organizations SINTEF and IFE, were found. Also, automotive publishing houses are important customers since they write about the vehicles and inform the public about the technology. The vehicles were regularly operated. During the project phase the ten B-Class F-CELLs accumulated a mileage of km. The technical performance of the vehicles has exceeded the expectations, especially in the cold Norwegian climate. Not a single problem occurred because of the low temperatures. Freeze start capability was proven. One of the projects aims was to have as many standard Mercedes-Benz processes as possible. The standard logistic process was successfully implemented. The vehicle repair took place in a normal Mercedes-Benz workshop with a fully trained technician. Nearly all repairs were handled on site at the workshop in Oslo. Several obstacles, such as getting Norwegian license plates even though Daimler Germany was still the formal owner of the vehicles, were overcome. A great joint achievement within the project was the revision of a statute in regards to parking below surfaces and driving through tunnels. The Fire Brigade officially stated that there are no more restrictions in this regard although it had been established just before the project had commenced. The customer expectation study showed that the customers are very happy with the vehicles and only little technical challenges in regards to the vehicles are left. The B-Class F-CELL vehicles will be operated well beyond the project duration. Lessons learned: At least two operational hydrogen refuelling stations per demonstration site are required to guarantee customer satisfaction

11 H2moves Scandinavia - Final Public Report 11 It is recommended to have additional Fuel Cell vehicles at the workshop for displaying to potential customers and as replacement vehicles for customers. The F-CELL functioned very well even in the cold climate of Norway, and most people were impressed with the smooth driving and comfort, and felt it was comparable to a conventional car. Even if the driving range is quite high, this is one of the major criticisms from the customers about the car - especially as there are quite few refuelling stations at this point in time. Although it is a relatively small market, Norway is an important pilot-market, with environmentally friendly people, who are very open for new technologies. 2.2 Hyundai ix35 FCEV Hyundai Motor Company (HMC) has targeted the European market for demonstrating and deploying fuel cell electric vehicles (FCEV) at an introductory stage of the early FCEV market. Background is that the European countries strongly support sustainable and clean energy provision politically and already has a well developed hydrogen infrastructure. The Scandinavian market, especially Denmark and Norway, is attractive for demonstrating and deploying FCEVs as both countries have the potential to produce hydrogen from renewable electricity and develop a hydrogen infrastructure with strong governmental support, such as by tax exemptions and incentives. Bearing these benefits in mind and targeting the European market led HME to consider a participation in the H2moves Scandinavia project as to demonstrate ix35 FCEVs both in Denmark and Norway. Hyundai Motor Europe (HME) has already started to participate in the H2moves Scandinavia project by demonstrating and deploying two ix35 FCEV in Herning and Copenhagen as early as by mid May The two customers of the two ix35 FCEV in Herning and Copenhagen are Hydrogen Link and the Danish Hydrogen and Fuel Cell Partnership, respectively. For the ix35 FCEVs deployed in Denmark a single type approval has been acquired from the Danish Transport Authority (DTA) for operating the FCEVs on public roads across Denmark. In addition to the deployment

12 H2moves Scandinavia - Final Public Report 12 in Denmark, HME has also provided two ix35 FCEV to Oslo in Norway by mid November The customers for these ix35 FCEVs are HyNor and ZERO. Also for these ix35 FCEVs a single type approval has been acquired from the Norwegian Public Road Administration (NPRA) for operation on public roads in Norway. For the maintenance of the four ix35 FCEVs operated for the H2mS project, HME has prepared a main workshop at the Offenbach headquarters in Germany as well as three local workshops in Herning (DK), Copenhagen (DK) and Oslo (NO). In all three local workshops hydrogen safety kits have been installed, including hydrogen detectors, a smart gas gateway and a portable defueling device. The hydrogen safety kit satisfies international hydrogen safety regulations. In addition to the workshops, one of the FCEV development engineers from Hyundai Motor Corporation s (HMC) R&D center in South Korea has moved to Offenbach on permanent basis responsible for the European maintenance. This dedicated fuel cell engineer has managed and supported the Offenbach and local workshops. The ix35 FCEVs operated for the H2mS project were equipped with a data monitoring system for collecting vehicle performance data. The data monitoring system was operated manually at an early stage of the project and in August 2012 been updated for automatic operation. All relevant vehicle performance data has automatically been transferred to a main server that monitors and manages the vehicle performance in-situ. The automatic data monitoring system has been developed for a simple handling of vehicle performance data offering the customer with convenient, safe and comfortable driving conditions. The four H2mS ix35 FCEVs have been developed and manufactured as testvehicles. As the ix35 FCEV use in H2mS was a pilot case for the European market, a service technician in the local workshop needed to be trained for handling the FCEVs. The FCEV engineer in HME Offenbach in turn has trained the service technicians in the local workshops. In case of serious malfunctions the local service technician could not repair her-/himself, the Offenbach based FCEV engineer supported the trained local technician by telephone. In cases when the FCEV engineer could not help the trained technician by telephone, the Offenbach based FCEV engineer needed to fly to the workshop, i.e. dubbed the flying doctor concept. In case, the vehicle could not be repaired at the local workshop, the vehicle was planned be towed to the central HME workshop in Offenbach. However, this fortunately has never happened in the course of H2mS. In case where a high level upgrade plan or higher technical support were needed, engineers from HMC in South Korea need to visit the local workshops for further support. The two ix35 FCEVs operated in Norway have been driven all the way from Oslo to Monaco without carrying an extra hydrogen tank on board. The total mileage of the

13 H2moves Scandinavia - Final Public Report 13 trip was approximately 2,200 km for each vehicle. The drivers from Zero only used the existing hydrogen refuelling station during the journey, and each of them by manual operation. The reason was that the refuelling interface between the vehicle and station (nozzle) was standardized but the communication between the vehicle and station were not. HME has also participated in the EU Hydrogen Road Tour organized by Hydrogen Sweden and LBST jointly with other automotive OEMs: Daimler, Toyota and Honda. During the tour, all partners have visited 5 countries and 9 cities in a period lasting about one month. During the city visits, all partners participated in VIP and public seminars and ride & drive events to promote the technical superiority of the FCEV technology and improve public awareness. In addition to visiting the cities, the partners have also participated in the Paris Motor Show, alongside a prominent Hyundai presentation of the FCEV at their own booth. The official project duration of the H2mS project is three years. As HME has only entered the project partnership in mid 2011, HME will extend the operation of the four ix35 FCEV in Denmark and Norway until the end of From the H2mS project, HME has taken home several strategic learnings for the future of operating FCEVs in Europe. First above all is the need to develop a tighter fuelling station network for customer satisfaction. More hydrogen refueling stations should be built to connect the major cities. The second issue is that no serious performance difference has been encountered between the operation experience between (northern) Europe and South Korea, especially bearing degradation also in harsher and fluctuating climate in mind. The ix35 FCEVs now have spent two winters in Denmark and Norway. During winter time, no serious performance degradation could be observed and sub-zero start up problem have not occurred. The third issue is that FCEV technology is still not well understood by the public. To overcome this weakness, it is therefore necessary to promote FCEV technology and improve public awareness. Finally, HME found that it took less maintenance costs for the four ix35 FCEV compared to what had been initially planned. The overall availability of FCEVs during the project is approximately 98% even considering that some of the components needed to be delivered from Korea. This means that fewer malfunctions have occurred during the project. In conclusion, not much maintenance cost was necessary for the fuel cell vehicle.

14 H2moves Scandinavia - Final Public Report BEV with fuel cell range extender To supplement the pure FCEV s from Daimler and Hyundai the H2MOVES project also featured the demonstration of five standard TH!NK Battery Electric Vehicles (BEV) that have been retrofitted with a fuel cell system and hydrogen storage for range extension. The addition of the fuel cell helped increase the range from ~110 km by an additional 140 km, giving a total range of 250 km. Also excess heat from the fuel cell system was utilized for cabin heating which helped reduce range impact in cold weather. Extensive results and lessons learned have been achieved during the entire process from manufacturing and homologation of the vehicles and during the operation. The manufacturing and homologation benefitted from past efforts conducted in Denmark on a similar vehicle set-up. The five TH!NK vehicles were therefore already put in operation in May 2011 and have been operated until tzhe end of the project in December The operation was however affected by the bankruptcy of the TH!NK company in June 2011, which made the provision of spare parts and servicing more challenging. Further the base BEV platform proved not to have the same quality as conventional vehicles which also affected the operation. The five vehicles in total have clocked 28,014 km with an uptime of 91% on average. Approximately 2/3 of the kilometres were driven on battery, and 1/3 with fuel cell range extension. The operation experience combined with further performance and price analyses however have shown that fuel cell plug-in hybrid vehicles or range extension may be a challenging concept. As the fuel cell has to be dimensioned to provide the peak power at high speed operation, the fuel cell cost will be similar to that of an FCEV. The only difference is the additional cost for the larger plug-in battery, which may be difficult to recover through savings in fuel cost when operating in battery mode.

15 H2moves Scandinavia - Final Public Report 15 3 Operation of Hydrogen Refuelling Stations 3.1 Stationary Refuelling Station Oslo Gaustad from H2 Logic As part of the project efforts H2 Logic constructed a large scale hydrogen refuelling station (HRS) in Oslo providing hydrogen for the FCEVs in the project. The effort provided extensive results and lessons learned across the entire process from site selection, HRS design and manufacturing to the final installation and operation. An extensive site screening of more than 30 sites in Oslo was firstly conducted to identify the most optimal location for the HRS. A suitable site was identified at the research organisation SINTEF in Gaustad in the western part of Oslo. The location was strategically well located with regards to the other HRS s in the city ensuring good refuelling coverage in Oslo. The HRS was manufactured, installed and operated by H2 Logic based on the company s H2Station technology. The HRS provides 70 MPa refuelling in accordance with the SAE J2601, and operation results have confirmed refuelling times consistently below four minutes for a full tank. The HRS includes onsite electrolysis production providing a 20 kg/day base load supply, with potentially additional trucking-in of hydrogen up to a total capacity of 200 kg/day. The installation of the HRS took 10 days in total, from arrival at site, until the first refuelling was conducted. This included local inspection by third parties and authorities as well as several days of hydrogen production and compression to reach the necessary refuelling pressure. Before opening a refuelling recommendation process was successfully conducted by Daimler. The HRS opened on 21 st November 2011 and is now in daily operation. Besides the FCH JU the HRS is also co-funded by the Norwegian Transnova and the Danish EUDP program.

16 H2moves Scandinavia - Final Public Report Moveable Refuelling Station from H2 Logic To provide refuelling during the European hydrogen vehicle demonstration tour H2 Logic developed and operated a Moveable hydrogen refuelling station (HRS). All the HRS equipment necessary for the refuelling is integrated into a compact station module allowing for easy transport and installation. The HRS is based on the H2Station technology from H2 Logic and offers 70 MPa refuelling in accordance with the SAE J2601 and can provide up to 50 kg/day with back-to-back refuelling (2x4 kg). In total the moveable HRS has been transported and installed at six different locations in four countries. During the H2mS European Road Tour the moveable refueller has been used at the Hannover and Copenhagen locations. The many locations proved the feasibility of the moveable concept. Installation time of down to only two days was achieved from arrival of the HRS to the first refuelling. The HRS worked flawless during the Road Tour with an uptime of 100% and conducting of several back-to-back refuellings.

17 H2moves Scandinavia - Final Public Report Improvement Options for Future Hydrogen Infrastructure Securing H 2 fuel gas quality at lower cost There are very strict requirements on the purity of hydrogen fuel in fuel cell vehicles: in fact, the relevant technical standard SAE J2719 prescribes levels of purity so high they approach the current state of the art in quantitative measurement of impurities in hydrogen. Certifying that a hydrogen sample from a HRS is compliant with this specification is therefore a complex, tedious and expensive endeavour, involving several cuttingedge measurement techniques. SINTEF has tested the hydrogen quality of three HRSs in the Greater Oslo area, which provide hydrogen from different sources. The tests were performed both inhouse, developing a long-path FTIR detector (see Figure 1), and for validation samples were sent to the only company in the world currently providing SAE J2719 certifications: Smart Chemistry Inc., of Sacramento, California. Figure 1: SINTEF's long-path (35 m) Fourier- Transform InfraRed (FTIR) gas cell, developed in H2moves Scandinavia. Whereas Smart Chemistry's approach is to use a full gamut of measurement techniques, SINTEF aimed at developing a simplified, cheaper and faster analytical protocol, which would make use of information on how the hydrogen is produced. This requires identifying canary constituents, i.e. compounds that are easily measured and can give a sufficiently precise estimate about other compounds that may be more difficult to quantify.

18 H2moves Scandinavia - Final Public Report 18 As for the actual hydrogen purity in the HRSs of the Greater Oslo area, each HRS failed the specification on at least one constituent; however, the violated parameters were related to inert gases (nitrogen and argon) and in one case to carbon dioxide; no catalyst poisons were detected above their prescribed levels Optimization of HRS operation with respect to electricity cost Production of hydrogen by water electrolysis is of special interest in Norway, which has historically had access to cheap, renewable electricity. SINTEF studied the electricity prices in Norway, the Northern Countries and Germany, and calculated which dimensioning criteria are most appropriate for the different cases. In particular, electricity prices in Germany are much more variable than in Norway: this makes it economically sound to acquire a larger electrolyser that can satisfy the hydrogen demand by running only at night, when electricity prices are lower, for the German electricity market; in Norway, it is more advantageous to run a minimally sized electrolyser continuously. Spot price time series HRS Grid... Power Conversion System + Vdc - Electrolyser + - H2 Hydrogen storage Spillage H2 Tank lorry H2O O2 H2 Fuel demand time series Figure 2: Integration of an HRS in the power grid. The dimensioning of HRSs was investigated also with respect to the randomness of the demand: drivers do not necessarily refuel when their hydrogen tank is empty, but may decide to refuel a half-full tank before a planned long trip, or simply because they are driving by the refuelling station that particular day. Other vehicles, such as city buses, have a much more predictable refuelling pattern. Several fleets of vehicles were simulated, and the results were used to determine how HRS should be dimensioned. In particular, it seems beneficial to dimension the electrolyser to be a bit (about 50%) oversized compared to its average production requirement, but not as much as to cover peak loads: it is economically sound to occasionally truck in hydrogen, even if it is much more expensive than producing it. The presence of buses in the fleet tends to require a more oversized system.

19 H2moves Scandinavia - Final Public Report 19 Finally, the possibility of using electrolysis-based HRSs as grid balancing units was investigated. The study identified immediate opportunities for frequency grid support (when there is too little or too much energy being produced compared to consumption), which may be expanded into fault support: in case of a major grid fault, HRSs can stop their hydrogen production immediately, thereby preventing a "domino effect". Voltage support (i.e. bringing voltage and current back in phase in the grid) is also possible, but requires retrofitting HRSs for this purpose Interaction between customers and HRSs in the Greater Oslo area An issue among early adopters of hydrogen-fuelled FCEVs is the limited number of HRSs. Drivers of such vehicles need to know where HRSs are, and whether they are operational before they decide to drive there to refuel. HRSs are more complex and require more maintenance than charging stations for battery electric vehicles (BEVs), so it is reasonable that there will be relatively few HRSs in the foreseeable future; also, since FCEVs have a much wider range than BEVs, drivers would need to memorise where HRSs are in a much larger area. The recent diffusion of smartphones equipped with GPS and internet connection allows solving this problem by storing information about HRSs in a central database, and then distributing it to users. Apps were developed for Android and ios (iphone), and are freely available from their respective App Stores under the keyword "H2where"; the apps offer the user a list of the nearest HRSs in operation, and can launch the GPS navigator to drive to an HRS selected by the user. The same information is available via the Web (h2where.info) and via SMS (only in Norway). Figure 3: Screenshot of the Android application, and the information distribution model.

20 H2moves Scandinavia - Final Public Report 20 The system is currently limited to the five HRSs in the Greater Oslo area, but can easily be extended to cover any number of HRSs. An account system is implemented to allow HRS operators to edit information about their stations via the website. The website and the smartphone app can also store user preferences such as the required hydrogen pressure (currently 700 or 350 bar), the maximum range to consider, the maximum price to pay for hydrogen fuel and the production method for hydrogen (electrolysis, reforming or industrial by-product).

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